ICCI 2014 FACS - 26/4/2014
Dynamic Heat Exchange SolutionsEnergy efficiency in the Turkish energy sector – the
effect of using innovative heat transfer solutions
Femke Schaëfer-Wering
Istanbul – April 26th , 2014
ICCI 2014 FACS - 26/4/2014
Topics:
• Short introduction to Bronswerk Heat Transfer®
• Why is energy efficiency improvement important?
• Improvement area’s for energy efficiency
• Solutions
ICCI 2014 FACS - 26/4/2014
Introduction
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
Our markets:
Sustainability Service & Maintenance
Power
Oil
Gas
Chemical
Air Handling
Food Processing
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
What we do:
• Thermal designs:
based on:
Aspen/HTFS
HTRI
HEI
Computational Fluid Dynamics
Hysys
ICCI 2014 FACS - 26/4/2014
What we do:
• Mechanical designs:
- ASME
- EN13445
- AD2000
- RTOD
- PD5500
- CODAP
- GOST
FEM analysis
ICCI 2014 FACS - 26/4/2014
What we do :
• Process design:
Process optimization
ICCI 2014 FACS - 26/4/2014
What we do :
• Equipment:
Heat exchangers
Air cooled coolers
And other process
equipment
ICCI 2014 FACS - 26/4/2014
What we do :
• Materials:
Titanium
(Super)Duplex
Nickel-Alloy
Inconel
Other exotics
ICCI 2014 FACS - 26/4/2014
What we do :
• Systems:
Incl. controls
ICCI 2014 FACS - 26/4/2014
What we do :
• Site work: Erection Assembly Start up Commissioning Service
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What we do :
• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist
maintenance for machines operating hazardous materials
ICCI 2014 FACS - 26/4/2014
Our focus on innovation:
• Product development
• System solutions
• New technology
ICCI 2014 FACS - 26/4/2014
Why is energy efficiency improvement important?
Two factors
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
Factor one: 20/20/20 targets for 2020 EU members
Turkey is candidate for EU-membership
20/20/20 targets for 2020
If Turkey becomes a member of the EU they are facing these targets
too
Emission of greenhouse gases
reduced by 20% compared to 1990
Energy efficiency
increased by 20%
20% of the energy needs to be
generated sustainably
ICCI 2014 FACS - 26/4/2014
Factor two: current status of Turkey
Growing population, economic growth, infrastructure lacking behind
Current population in
Turkey: over 76 million
Expectation for 2050
growth until: 93 million
Expectation for 2075 slow
down to: 89 million
ICCI 2014 FACS - 26/4/2014
Factor two: current status of Turkey
Growing population, economic growth, infrastructure lacking behind
Current population in
Turkey: over 76 million
Expectation for 2050
growth until: 93 million
Expectation for 2075 slow
down to: 89 million
Turkey currently: 15th
economy in the world,
Fastest growing - growth in
2013: 4,4%
Expectation for 2050: 9th
economy in the world
ICCI 2014 FACS - 26/4/2014
Factor two: current status of Turkey
Growing population, economic growth, infrastructure lacking behind
Current population in
Turkey: over 76 million
Expectation for 2050
growth until: 93 million
Expectation for 2075 slow
down to: 89 million
Turkey currently: 15th
economy in the world,
Fastest growing - growth in
2013: 4,4%
Expectation for 2050: 9th
economy in the world
30% of energy imported
Wants to become self-sufficient:
Nuclear, geothermal, hydro, coal
and waste to energy
Patriotic duty to produce more
energy and reduce energy
consumption
Turkey Electricity Production Map
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Turkey Electricity Installed Power Chart
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Installed power capacity : 61.422 MW (30.09.2013)
Expected power increase : 50.000 MW (end of 2020)
TOTAL : 111.422 MW (end of 2020)
Area’s for improvement
ICCI 2014 FACS - 26/4/2014
One: Newbuilds
Start at the design: reducing energy consumption of process equipment
Fans of the air cooled coolers,
condensers & combustion blowers
Pumps
Our high efficiency fans reduce
energy consumption by 50%
Our high efficiency pumps
reduce energy consumption
by 20-40%
ICCI 2014 FACS - 26/4/2014
Two: Upgrading of Installation
High efficiency fans & pumps: increase plant capacity and efficiency
Approx. 200 kW per condenser
Approx. 600 kW combustion
blowers
Approx. 1000 kW pumps
Use these kW’s more efficiently
Increasing output
ICCI 2014 FACS - 26/4/2014
Overall Plant Performance
Improve plant efficiency; increasing the overall efficiency by 6%
The plant efficiency is approx. 30-40%
2% is used for fans of the
condenser
6% is used for the fans of the
combustion blowers
Saving 50% on fan power
10% is used for pumps
Saving 20% on pumping power
Increase overall efficiency by 6%
ICCI 2014 FACS - 26/4/2014
Solutions
High efficiency cooling
ICCI 2014 FACS - 26/4/2014
Current situation:
Huge plot space requirement
High power consumption for air coolers &
combustion blowers
Big influence on CAPEX & OPEX
High efficiency cooling
ICCI 2014 FACS - 26/4/2014
High efficiency cooling
New fan design based on
aerospace technology:
the Whizz-Wheel®
Intensified heat transfer
Over 50% reduction in
power consumption
OR
Over 30% plot space
reduction
ICCI 2014 FACS - 26/4/2014
Benefits;
Size reduction: 30 %
Power consump. red.: 50% =
500 kW
Opex savings: € 320.000,-
/ yr
In 10 years: € 3.200.000,-
Noise reduction: 7 dB(A) Figure 3: comparative
Figure 2: high efficiency designFigure 1: standard design
High efficiency cooling
ICCI 2014 FACS - 26/4/2014
Debottlenecking & Increasing output
ICCI 2014 FACS - 26/4/2014
Increasing output
35% more cooling air
10-15% more production output
€ 700 million gas production
€ 70 million additional
Debottlenecking investment: € 5,5 million
ICCI 2014 FACS - 26/4/2014
Increasing output
Restrictions:
Maximum noise level
Production capacity
down to 60%
Results:
Elimination of all
noise issues
Production up to
100%
Bonus:
56% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014
Increasing output
Restrictions:
Lower noise level or
plant shut down!
Results:
Elimination of all
noise issues
Bonus:
53% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014
Compressors/turbines
ICCI 2014 FACS - 26/4/2014
Energy recovery from gas reduction
• Several hundreds of millions m3
pressurized gas in pipelines
• Gas at 20-80 Bar
• Increase or decrease pressure
before entering the gasturbine
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Energy recovery from gas reduction
Radiax ®compressor/turbine
Global Refining Summit 2014 FACS - 31/3/2014
Global Refining Summit 2014 FACS - 31/3/2014
Radiax®compressor/turbine
Summary
Turkey needs power
Turkey needs energy efficiency
There are two area’s for improvement: Start at the design Upgrading the installation Resulting in: Overall improved plant performance
Bronswerk can help in three ways: High efficiency cooling Debottlenecking Compressors/turbines
ICCI 2014 FACS - 26/4/2014
Summary
Yes, Bronswerk Heat Transfer can help your power plant become more energy efficient and profitable at the same time:
High efficiency
cooling
Debottlenecking Compressors/turbines
Power consumption
reduction over 50%
Elimination of all
noise issues
Energy recovery of lost
Size reduction up to
30 %
Improved production
production capacity
capacity > 100%
Size reduction up to
80%
Noise reduction:
7 dB(A)
Bonus: savings in
energy consumption
consumption
ICCI 2014 FACS - 26/4/2014
Thank you for your attention.Questions please
ICCI 2014 FACS - 26/4/2014
How to contact us:
www.bronswerk.com
facebook.com/bronswerk
Linkedin.com/company/bronswerk-heat-transfer
twitter.com/bronswerk
And come visit our booth in hall 10 number: A 107
ICCI 2014 FACS - 26/4/2014
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